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www.alfalaval.com
− Brewery Systems
29/04/2021 | © Alfa Laval 1 |
Fermentation cellar design Alexander Stogniy,
Global Sales Manager, Brewery systems
Denis Martin,
Crafts Modules Manager, Brewery systems
www.alfalaval.com
The brewery cold block− From wort cooling to packaging
| © Alfa Laval29/04/2021 2 |
Stable quality
Food safety
and hygiene
Sustainability
www.alfalaval.com
Custom turnkey solutions for the cold block− From wort cooling to packaging
Optimizing process design for
new or existing facilities
• Biological contamination
• Oxygen pick up
• Product losses
• Yeast management
• Fermentation efficiency
• Product stabilization
• Cleaning-in-Place (CIP) efficiency
• Water and energy consumption
• Waste stream management
• Other areas
| © Alfa Laval29/04/2021 3 |
www.alfalaval.com
What we’ll talk about today− Agenda
| © Alfa Laval29/04/2021 4 |
• Fermentation tanks layout and
installation options
• Pipe bridges and piping layout
• State of the art valve cluster design– Product routing
– CIP and gas routing
– CIP
• Features of sustainable design
www.alfalaval.comwww.alfalaval.com29/04/2021 | © Alfa Laval 5 |
Tank layout
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Tank layout− Plan now for the future
• Future brewery development
and expansion
• Maintenance and site logistics
• Installation plan optimization
• Length of piping = operation
efficiency and waste
management
| © Alfa Laval29/04/2021 6 |
www.alfalaval.com
Extension
Tip 1 – optimize space usage− What to consider when choosing an optimal tank layout
• Position equipment for easier
installation and service
• Plan for possible pipe routes, filling and
emptying distances
• Consider future extension capabilities
| © Alfa Laval29/04/2021 7 |
www.alfalaval.com
Tip 2 – tank grouping− Tank layout
| © Alfa Laval29/04/2021 8 |
Valve cluster
Valve cluster
Valve cluster
Valve cluster
Valve cluster
Valve cluster
Pump
Valve cluster
Valve cluster
Valve cluster
Valve cluster
Pump
Pump Brewhouse
Brewhouse
Existing
New
Existing
New
Option 2Option 1
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Tip 3 – process and CIP flexibility− Tank layout
| © Alfa Laval29/04/2021 9 |
Pump
www.alfalaval.comwww.alfalaval.com29/04/2021 | © Alfa Laval 10 |
Pipe bridges and
piping layout
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Pipe bridges and piping layout− Example
Leave adequate space
for future:
• Pipes
• Walkways
• Maintenance
• Electrical hardware
| © Alfa Laval29/04/2021 11 |
Filtration
CIP
Brewhouse
Glycol
supply
Main pipe bridge
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Pipe bridges and piping layout− Important for all breweries
| © Alfa Laval29/04/2021 12 |
www.alfalaval.com
Piping layout− Expansion loops
| © Alfa Laval29/04/2021 13 |
Wort line
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Pipe bridges and piping layout− Craft brewery example
Well-designed pipe bridges and piping
layout means cellar design that is:
• Safe
• Efficient
• Expandable
| © Alfa Laval29/04/2021 14 |
What to avoid
www.alfalaval.comwww.alfalaval.com29/04/2021 | © Alfa Laval 15 |
Tank installation options
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Tank installation options− Investments and complexity
Slab-mounted tanks
• Smaller building to maintain,
less OPEX
• More space for equipment and
piping underneath the tanks
• Higher CAPEX
| © Alfa Laval29/04/2021 16 |
Leg-mounted tanks
• Larger building to maintain
• Higher OPEX
• Less space for equipment and
piping underneath the tanks
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Tank installation options− Installation and safety
| © Alfa Laval29/04/2021 17 |
Slab-mounted tanks
• Physical separation between
installation crews
• Improved installation time
• Better control of site safety
Leg-mounted tanks
• Complex safety management
if tanks are built on site
• Increased installation time
www.alfalaval.comwww.alfalaval.com29/04/2021 | © Alfa Laval 18 |
Valve clusters for process routing
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Product valve cluster design− Loop design
Advantages when the tank outlet
pipe is separated from the tank
• Reduced extract losses due to
more efficient product push outs
and recovery
• Best cleanability and CIP efficiency
• Increased product quality – no
product is left in the pipe during
fermentation
| © Alfa Laval29/04/2021 19 |
Surplus yeast
Additive
Tank CIP
return Wort
Deaerated
water
Green
beer
Yeast
harvest
CIP supply
tank loop
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Product valve cluster design− Loop design for full process flexibility and hygiene
| © Alfa Laval29/04/2021 20 |
Tank loop hot
CIP supply
(from CIP 4)
Tank cold
CIP return
(to CIP 5)
8 m
Green beer
transfer line
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Product valve cluster design− Push out and prime lines for reduced product loss
| © Alfa Laval29/04/2021 21 |
Additive
Deaerated
water
Wort
Tanks CIP
return
Green
beer
Yeast
harvest
Surplus
yeast
CIP supply
tank loop
Green
beer
transfer
line
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Product valve cluster design and tank outlet− Tank outlet operation
| © Alfa Laval29/04/2021 22 |
Green beer block
as close as
possible to the
tank prevents
losses
Deaerated water
purge line as close as
possible to the tank
minimizes water
consumption
Tank outlet
mixproof valve
opens to allow
green beer flow to
main valve cluster
Green beer to main
valve cluster
Yeast to main
valve cluster
Deaerated water
purge line as close as
possible to the tank
minimizes water
consumption
Tank outlet mixproof
valve opens to allow
yeast flow to main
valve cluster
Yeast block as
close as possible
to the tank
prevents
losses
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Product valve cluster design and tank outlet− Sampling and drains
| © Alfa Laval29/04/2021 23 |
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Valve cluster design and new tank outlet
| © Alfa Laval29/04/2021 24 |
From
tank
CIP
return
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Valve cluster design and combined loop− Easy cleanability, reduced water consumption and minimized product loss
| © Alfa Laval29/04/2021 25 |
Four tanks connectedTwo tanks connected
www.alfalaval.comwww.alfalaval.com29/04/2021 | © Alfa Laval 26 |
Valve clusters for CIP and gas routing
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CIP and gas valve cluster design− Vertical
| © Alfa Laval29/04/2021 27 |
• More lightweight piping
• More compact installation
• Easier installation due to pipes from above
• Easier access for valve maintenance
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CIP and gas valve cluster design− Vertical
| © Alfa Laval29/04/2021 28 |
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CIP and gas valve cluster design− Horizontal
| © Alfa Laval29/04/2021 29 |
CIPCIP
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Valve cluster design and maintenance− Horizontal
• No splashing around
the cluster
• Convenient maintenance
platforms
| © Alfa Laval29/04/2021 30 |
www.alfalaval.com
CO2 recovery line and exhaust line cleaning
| © Alfa Laval29/04/2021 31 |
Fermentation
tankFoam
trap
CO2 recovery
CO2 recovery
CIP supply CIP return
• No pressure
build-up in CO2
recovery lines
• Full cleanability
by hot CIP
• Applied to all gas
lines
CO2 recovery
CIP return
CIP supply
www.alfalaval.comwww.alfalaval.com29/04/2021 | © Alfa Laval 32 |
Sampling options
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Sampling options for automatic cellars
| © Alfa Laval29/04/2021 33 |
Complete automatic centralized
sampling, including CIP and
sterilization requires no operator
intervention
Sampling with manual
connection for cleaning
requires operator to connect
sampling valve to the CIP pipe
Sampling at each tank with
automatic CIP does not require
operator to connect sampling
valve for CIP
Alfa Laval offers three alternatives for sampling from the fermentation tanks along with cleaning-in-place
1 2 3
www.alfalaval.com
Sampling options
| © Alfa Laval29/04/2021 34 |
• Sampling at floor level
• No manual operation required for cleaning
• Effective CIP cleaning during the tank CIP
www.alfalaval.com
Sampling from fermenters− Detailed view
| © Alfa Laval29/04/2021 35 |
Sampling from the cone
or shell on the big tanks
CIP, during the tank CIP
DN25/10
DN80/25
CIP supply
www.alfalaval.comwww.alfalaval.com29/04/2021 | © Alfa Laval 36 |
Density control in fermentation tanks
www.alfalaval.com
Density control
• Based on high-quality
vibration sensor
• Affordable technology
• Easy to integrate
• High precision
| © Alfa Laval29/04/2021 37 |
DP
Density probe
www.alfalaval.comwww.alfalaval.com29/04/2021 | © Alfa Laval 38 |
Fermentation cellar construction sets
www.alfalaval.com
Fermentation cellar construction sets− Pre-engineered piping and instrumentation diagrams
Optimal solutions for specific projects
• Many design options
• Range of automation
• Verified hygienic designs
Why pre-engineered construction sets?
• Highest hygienic standards
• Production flexibility
• Product quality
• Operational safety
| © Alfa Laval29/04/2021 39 |
www.alfalaval.com
Fermentation cellar design− Summary
Efficient, sustainable, easily expandable and
maintenance-friendly
• Take a holistic approach to tank layout – today
and tomorrow
• Choose the right installation option: slab-mounted
or leg-mounted installation?
• Plan the pipe bridges and piping layout to
make installation easy and create more space
in the cellar
• Design valve clusters for optimal operation and
minimize use of water and energy
• Automatic density control for better cellar
performance
| © Alfa Laval29/04/2021 40 |
www.alfalaval.com
Cold blocks around the world− Alfa Laval installations
Aldox
>900since 1990
Engineered solutions
IMXD
Dry hopping
>50since 2017
Flexitherm
>500since 1990
Iso-Mix
Fermentation
>500since 2010
Carboblend,
Carboset and Alex
>300since 1990
Decanter
Intelligent Whirlpool
Systems
>25since 2012
Tank top systems
>3,200since 2011
BSF
>120since 1990
HSS
>390since 2012
Yards
Carib
Breweries
Heineken
Rwanda
Carlsberg
Poland
Carlsberg
Belarus
Efes
Turkey
Baltika
Brewery
Heineken
AibaHeineken
Ota
Unicer
Porto
Heineken
Panama
Tunis
Ambev
Ponta Grossa
Heineken
Surinam
Modelo
Yucateca
Westmalle
Asahi
Australia
Faxe
Denmark
Heineken
Indonesia
AB InBev
Australia
Complete process block
ABInBev
Karnataka
CG Brewery
Nepal
AB InBev
Wuhan
Master India
Brewing
AB InBev
Leuven
Ambev
Sete Lagoas Ambev
Nova Rio
Modelo
Zacatecas
Modelo
Centro
Diageo
Ireland
Duvel
AB InBev
Mozambique
Province Brands
Canada
| © Alfa Laval29/04/2021 41 |
www.alfalaval.com
Any further questions
Please feel free to contact:
| © Alfa Laval29/04/2021 42 |
Alexander Stogniy
Global Sales Manager
Alfa Laval Brewery Systems
+45 277 786 94
Denis Martin
Crafts Modules Manager
Alfa Laval Brewery Systems
+45 395 365 83
Visit our web page for more information
www.alfalaval.comwww.alfalaval.com29/04/2021 | © Alfa Laval 43 |
Q&A
www.alfalaval.com
Webinars for brewers− Upcoming events
| © Alfa Laval29/04/2021 44 |
Beer concentration with Revos™ – the
future of beer production and distributionWebinar 17 June, 2021
Click here to visit the webinar web page
www.alfalaval.com